US4104430A - Vacuum formable materials - Google Patents

Vacuum formable materials Download PDF

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Publication number
US4104430A
US4104430A US05/583,126 US58312675A US4104430A US 4104430 A US4104430 A US 4104430A US 58312675 A US58312675 A US 58312675A US 4104430 A US4104430 A US 4104430A
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United States
Prior art keywords
foam
fabric
vinyl chloride
chloride polymer
layer
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Expired - Lifetime
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US05/583,126
Inventor
Sidney Desmond Fenton
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Storey Brothers and Co Ltd
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Storey Brothers and Co Ltd
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Publication date
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Priority to US05/583,126 priority Critical patent/US4104430A/en
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/12—Layered products comprising a layer of synthetic resin next to a fibrous or filamentary layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/06—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B27/065—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material of foam
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/30—Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers
    • B32B27/304—Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers comprising vinyl halide (co)polymers, e.g. PVC, PVDC, PVF, PVDF
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form
    • B32B3/26—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer
    • B32B3/30—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer characterised by a layer formed with recesses or projections, e.g. hollows, grooves, protuberances, ribs
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
    • B32B5/245—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it being a foam layer
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06M—TREATMENT, NOT PROVIDED FOR ELSEWHERE IN CLASS D06, OF FIBRES, THREADS, YARNS, FABRICS, FEATHERS OR FIBROUS GOODS MADE FROM SUCH MATERIALS
    • D06M23/00—Treatment of fibres, threads, yarns, fabrics or fibrous goods made from such materials, characterised by the process
    • D06M23/16—Processes for the non-uniform application of treating agents, e.g. one-sided treatment; Differential treatment
    • D06M23/18—Processes for the non-uniform application of treating agents, e.g. one-sided treatment; Differential treatment for the chemical treatment of borders of fabrics or knittings; for the thermal or chemical fixation of cuttings, seams or fibre ends
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/02—Synthetic macromolecular fibres
    • B32B2262/0261—Polyamide fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2266/00—Composition of foam
    • B32B2266/02—Organic
    • B32B2266/0214—Materials belonging to B32B27/00
    • B32B2266/0221—Vinyl resin
    • B32B2266/0235—Vinyl halide, e.g. PVC, PVDC, PVF, PVDF
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2266/00—Composition of foam
    • B32B2266/02—Organic
    • B32B2266/0214—Materials belonging to B32B27/00
    • B32B2266/0278—Polyurethane
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2266/00—Composition of foam
    • B32B2266/06—Open cell foam
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2309/00—Parameters for the laminating or treatment process; Apparatus details
    • B32B2309/08—Dimensions, e.g. volume
    • B32B2309/10—Dimensions, e.g. volume linear, e.g. length, distance, width
    • B32B2309/105—Thickness
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
    • Y10T428/24628—Nonplanar uniform thickness material
    • Y10T428/24636—Embodying mechanically interengaged strand[s], strand-portion[s] or strand-like strip[s] [e.g., weave, knit, etc.]
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
    • Y10T428/24942—Structurally defined web or sheet [e.g., overall dimension, etc.] including components having same physical characteristic in differing degree
    • Y10T428/2495—Thickness [relative or absolute]
    • Y10T428/24967—Absolute thicknesses specified
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/249921—Web or sheet containing structurally defined element or component
    • Y10T428/249953—Composite having voids in a component [e.g., porous, cellular, etc.]
    • Y10T428/249987—With nonvoid component of specified composition
    • Y10T428/249988—Of about the same composition as, and adjacent to, the void-containing component
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/249921—Web or sheet containing structurally defined element or component
    • Y10T428/249953—Composite having voids in a component [e.g., porous, cellular, etc.]
    • Y10T428/249987—With nonvoid component of specified composition
    • Y10T428/249991—Synthetic resin or natural rubbers
    • Y10T428/249992—Linear or thermoplastic
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/31504—Composite [nonstructural laminate]
    • Y10T428/31725—Of polyamide
    • Y10T428/31739—Nylon type
    • Y10T428/31743—Next to addition polymer from unsaturated monomer[s]
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/31504—Composite [nonstructural laminate]
    • Y10T428/31855—Of addition polymer from unsaturated monomers
    • Y10T428/31909—Next to second addition polymer from unsaturated monomers
    • Y10T428/31913—Monoolefin polymer
    • Y10T428/3192—Next to vinyl or vinylidene chloride polymer
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/31504—Composite [nonstructural laminate]
    • Y10T428/31855—Of addition polymer from unsaturated monomers
    • Y10T428/31909—Next to second addition polymer from unsaturated monomers
    • Y10T428/31928—Ester, halide or nitrile of addition polymer
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/31504—Composite [nonstructural laminate]
    • Y10T428/31855—Of addition polymer from unsaturated monomers
    • Y10T428/31935—Ester, halide or nitrile of addition polymer
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
    • Y10T442/40—Knit fabric [i.e., knit strand or strip material]
    • Y10T442/469—Including a foamed layer or component

Definitions

  • This invention relates to a vacuum formable material.
  • a vacuum formable material comprising a laminate of a stretchable fabric, a plasticized vinyl chloride polymer layer and sandwiched between them a plastics foam layer.
  • This material can be vacuum formed to shape to give a shaped material which has a luxurious and ⁇ full ⁇ feel.
  • the stretchability of the fabric will be chosen in dependance upon this extent to which the material is to be drawn during vacuum forming. Thus for materials which do not need to be deeply drawn, e.g. in the formation of a panel for the top of a seat cover, a ready stretchability of at least about 5% in at least one direction, and preferably in two directions at right angles to one another, under a 5 lb load for a 2 inch wide strip is usually sufficient; such a fabric can be a knitted fabric such as a knitted nylon fabric of 30 denier yarn having 61 courses and 42 wales per inch and weighing 2.4 oz/sq. yard or a knitted nylon fabric having 68 stitches per inch and 81 rows per inch and weighing 5.5. oz/square yard.
  • an extensibility of, at least 20% and preferably 25% in at least one direction and preferably in two directions at right angles to one another, for a 2 inch wide strip under a load of 5 lb is desirable; such a fabric can be obtained by forming the fabric from yarns, filaments or the like which are readily extensible because they are highly crimped or coiled, e.g. highly crimped nylon 6 yarns or coiled yarns or by forming the fabric in such a way as to have high extensibility, e.g. by twill or sateen weaving or by using non-woven fabrics. Naturally fabrics having extensibilities or stretchabilities between these limits can be used depending upon the extent to which the material is drawn.
  • the plasticized vinyl chloride polymer is preferably polyvinyl chloride but could be a copolymer of vinyl chloride.
  • This can be a cast film or calandered sheet and is preferably from 0.1 to 2 mm in thickness. It is preferably a cast film, however, since the resulting sheet can then contain a much higher proportion of plasticizer than a calandered sheet and so be much softer and more pliable.
  • the foam layer sandwiched between the fabric and the vinyl chloride polymer layer is preferably a polyurethane (polyether or polyester urethane) or a vinyl chloride polymer.
  • the foam can be a closed cell foam but is preferably an open-celled foam. In the case of the latter type of foam the material has the advantage that the fabric layer and foam are porous or breathable and so when the material of the invention is used as a cover for upholstered items this can provide increased comfort.
  • the foam layer can for example be from 1 to 20 mm thick.
  • the materials of the invention can be prepared in a number of ways by laminating the components.
  • the foam layer is formed, e.g. by foaming a layer of foamable material or by slicing a veneer of foam from a mass of foams, the fabric can then be adhered to one side of the foam layer, e.g. by using an adhesive or by flame softening the surface of the foam to make it sticky and finally a cast or caelered vinyl chloride polymer sheet can be adhered to the other surface of the foam layer, e.g. by an adhesive or by laminating to the foam and fabric laminate while the vinyl chloride polymer sheet is still hot and sticky after being gelled.
  • the vacuum formable material is particularly useful in the preparation of covers for upholstered and padded items such as car seats and in this connection it can be used in the preparation of such items in the manners described in our copending patent application Nos. 36525/71, 36526/71, 6544/72, 4929/73 and 4930/73.
  • the material of the invention will normally be used with the fabric side of the laminate outermost.
  • a vacuum formable material according to the invention is shown, by way of example, in cross-section in the accompanying FIGURE.
  • the material 10 is a laminate of an outer fabric layer 12 and an outer cast plasticized polyvinyl chloride sheet 14 between which is a plastics foam layer 16.

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  • Chemical & Material Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • General Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Laminated Bodies (AREA)

Abstract

The preparation of a laminate which can be shaped by vacuum forming is described. The laminate is of a stretchable fabric, a plasticized vinyl chloride polymer layer and sandwiched between them a plastics foam layer. Such a material has a luxurious and "full" feel even after shaping.

Description

This invention relates to a vacuum formable material.
According to the invention there is provided a vacuum formable material comprising a laminate of a stretchable fabric, a plasticized vinyl chloride polymer layer and sandwiched between them a plastics foam layer.
This material can be vacuum formed to shape to give a shaped material which has a luxurious and `full` feel.
The stretchability of the fabric will be chosen in dependance upon this extent to which the material is to be drawn during vacuum forming. Thus for materials which do not need to be deeply drawn, e.g. in the formation of a panel for the top of a seat cover, a ready stretchability of at least about 5% in at least one direction, and preferably in two directions at right angles to one another, under a 5 lb load for a 2 inch wide strip is usually sufficient; such a fabric can be a knitted fabric such as a knitted nylon fabric of 30 denier yarn having 61 courses and 42 wales per inch and weighing 2.4 oz/sq. yard or a knitted nylon fabric having 68 stitches per inch and 81 rows per inch and weighing 5.5. oz/square yard. For materials which are to be deeply drawn, e.g. in the formation of a one piece cover for a seat, an extensibility of, at least 20% and preferably 25% in at least one direction and preferably in two directions at right angles to one another, for a 2 inch wide strip under a load of 5 lb is desirable; such a fabric can be obtained by forming the fabric from yarns, filaments or the like which are readily extensible because they are highly crimped or coiled, e.g. highly crimped nylon 6 yarns or coiled yarns or by forming the fabric in such a way as to have high extensibility, e.g. by twill or sateen weaving or by using non-woven fabrics. Naturally fabrics having extensibilities or stretchabilities between these limits can be used depending upon the extent to which the material is drawn.
The plasticized vinyl chloride polymer is preferably polyvinyl chloride but could be a copolymer of vinyl chloride. This can be a cast film or calandered sheet and is preferably from 0.1 to 2 mm in thickness. It is preferably a cast film, however, since the resulting sheet can then contain a much higher proportion of plasticizer than a calandered sheet and so be much softer and more pliable.
The foam layer sandwiched between the fabric and the vinyl chloride polymer layer is preferably a polyurethane (polyether or polyester urethane) or a vinyl chloride polymer. The foam can be a closed cell foam but is preferably an open-celled foam. In the case of the latter type of foam the material has the advantage that the fabric layer and foam are porous or breathable and so when the material of the invention is used as a cover for upholstered items this can provide increased comfort.
The foam layer can for example be from 1 to 20 mm thick. The thicker the layer the more luxurious the "feel" of the resulting shaped material but on the other hand the thicker this foam layer becomes, the less possible it is to incorporate finely detailed shaping into a shaped cover formed by vacuum forming the material of the invention.
The vacuum forming of a sheet material by heating it to soften it and then drawing it down into a female mould or over a male mould is well known and needs no further explanation. The equivalent excess fluid pressure process in which an excess fluid pressure is used to force the softened sheet material into or over a mould is to be considered herein to be embraced by the term "vacuum forming".
The materials of the invention can be prepared in a number of ways by laminating the components. According to preferred ways of making the materials, the foam layer is formed, e.g. by foaming a layer of foamable material or by slicing a veneer of foam from a mass of foams, the fabric can then be adhered to one side of the foam layer, e.g. by using an adhesive or by flame softening the surface of the foam to make it sticky and finally a cast or calandered vinyl chloride polymer sheet can be adhered to the other surface of the foam layer, e.g. by an adhesive or by laminating to the foam and fabric laminate while the vinyl chloride polymer sheet is still hot and sticky after being gelled.
The vacuum formable material is particularly useful in the preparation of covers for upholstered and padded items such as car seats and in this connection it can be used in the preparation of such items in the manners described in our copending patent application Nos. 36525/71, 36526/71, 6544/72, 4929/73 and 4930/73. The material of the invention will normally be used with the fabric side of the laminate outermost.
A vacuum formable material according to the invention is shown, by way of example, in cross-section in the accompanying FIGURE. The material 10 is a laminate of an outer fabric layer 12 and an outer cast plasticized polyvinyl chloride sheet 14 between which is a plastics foam layer 16.
A latitude of modification, change and substitution is intended in the foregoing disclosure and in some instances some features of the invention will be employed without a corresponding use of other features. Accordingly it is appropriate that the appended claims be construed broadly and in a manner consistent with the spirit and scope of the invention herein.

Claims (9)

What I claim is:
1. A vacuum formed laminate from a material comprising:
a. a stretchable fabric having a ready stretchability of at least 20% in at least about one direction under a 5 lb load for a 2 inch wide strip,
b. a cast plasticized vinyl chloride polymer layer which is 0.1 to 2 mm thick, and
c. sandwiched between said fabric and said layer, a plastic foam layer which is from 1 to 20 mm thick.
2. A material according to claim 1 in which said vinyl chloride polymer is polyvinyl chloride.
3. A material as claimed in claim 1 in which said foam is an open-celled foam.
4. A material as claimed in claim 1 in which said plastics foam has been chosen from a polyurethane foam and a vinyl chloride polymer foam.
5. The material of claim 1 wherein said stretchable fabric has a ready stretchability of at least about 5% in two directions at right angles to each other under a 5 lb. load for a two inch wide strip.
6. The material of claim 5 wherein said stretchable fabric is a knitted nylon fabric.
7. The material of claim 1 wherein said stretchable fabric has a ready stretchability of at least 25% in two directions at right angles to one another for a two inch wide strip under a load of 5 lbs.
8. The material of claim 7 wherein said stretchable fabric is a highly crimped nylon yarn.
9. A material of claim 1 wherein said foam is an open-celled foam and is selected from the group consisting of polyurethane foam and vinyl chloride polymer foam.
US05/583,126 1975-06-02 1975-06-02 Vacuum formable materials Expired - Lifetime US4104430A (en)

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Cited By (22)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4284681A (en) * 1979-06-26 1981-08-18 Dycem Limited Composite sheet material
US4316926A (en) * 1979-01-25 1982-02-23 Bernard Kaminstein Non-slip material for the hand
US4656086A (en) * 1986-07-21 1987-04-07 United Technologies Automotive, Inc. Cloth covered pinch welt and method for making same
US4690847A (en) * 1986-06-26 1987-09-01 Burlington Industries, Inc. Cold weather garment structure
US4740417A (en) * 1986-07-22 1988-04-26 Cone Mills Corporation Thermoplastic vacuum molding method and article produced thereby
EP0251640A3 (en) * 1986-06-26 1988-09-14 Burlington Industries, Inc. Cold weather garments
US4865904A (en) * 1986-09-10 1989-09-12 Sunstar Giken Kabushiki Kaisha Laminated cloth
US4880680A (en) * 1988-05-23 1989-11-14 Sota Technology, Inc. Article of manufacture and method for encasing same
US4921752A (en) * 1988-08-11 1990-05-01 Milliken Research Corporation Laminated seat fabric
US4935287A (en) * 1989-08-30 1990-06-19 Minnesota Mining And Manufacturing Company Stretchable laminate constructions
US5554145A (en) * 1994-02-28 1996-09-10 The Procter & Gamble Company Absorbent article with multiple zone structural elastic-like film web extensible waist feature
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WO1997036740A1 (en) * 1996-04-03 1997-10-09 Rubie's Costume Co., Inc. Costumes with semi-rigid fabric components and method for manufacture of same
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US5731062A (en) * 1995-12-22 1998-03-24 Hoechst Celanese Corp Thermoplastic three-dimensional fiber network
US5876391A (en) * 1993-11-19 1999-03-02 The Procter & Gamble Company Absorbent article with structural elastic-like film web waist belt
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US6342287B1 (en) * 1996-09-27 2002-01-29 Pandrol Limited Elastic pad, especially under-rail
WO2004098869A1 (en) 2003-05-05 2004-11-18 North Carolina State University Three-dimensional deep molded structures with enhanced properties
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US4740417A (en) * 1986-07-22 1988-04-26 Cone Mills Corporation Thermoplastic vacuum molding method and article produced thereby
US4865904A (en) * 1986-09-10 1989-09-12 Sunstar Giken Kabushiki Kaisha Laminated cloth
US4880680A (en) * 1988-05-23 1989-11-14 Sota Technology, Inc. Article of manufacture and method for encasing same
US4921752A (en) * 1988-08-11 1990-05-01 Milliken Research Corporation Laminated seat fabric
US4935287A (en) * 1989-08-30 1990-06-19 Minnesota Mining And Manufacturing Company Stretchable laminate constructions
US6027483A (en) * 1993-08-03 2000-02-22 Chappell; Charles W. Web materials exhibiting elastic-like behavior
US5916663A (en) * 1993-08-03 1999-06-29 Chappell; Charles W. Web materials exhibiting elastic-like behavior
US5891544A (en) * 1993-08-03 1999-04-06 The Procter & Gamble Company Web materials exhibiting elastic-like behavior
US5691035A (en) * 1993-08-03 1997-11-25 The Procter & Gamble Company Web materials exhibiting elastic-like behavior
US5723087A (en) * 1993-08-03 1998-03-03 The Procter & Gamble Company Web materials exhibiting elastic-like behavior
US5876391A (en) * 1993-11-19 1999-03-02 The Procter & Gamble Company Absorbent article with structural elastic-like film web waist belt
US5904673A (en) * 1993-11-19 1999-05-18 The Procter & Gamble Company Absorbent article with structural elastic-like film web waist belt
US6325787B1 (en) 1994-02-28 2001-12-04 The Procter & Gamble Company Absorbent article with multiple zone structural elastic-like film web extensible waist feature
US5749866A (en) * 1994-02-28 1998-05-12 The Procter & Gamble Company Absorbent article with multiple zone structural elastic-like film web extensible waist feature
US6706028B2 (en) 1994-02-28 2004-03-16 The Procter & Gamble Company Absorbent article with multiple zone structural elastic-like film web extensible waist feature
US20040224132A1 (en) * 1994-02-28 2004-11-11 Roe Donald Carroll Absorbent article with multiple zone structural elastic-like film web extensible waist feature
US7527615B2 (en) 1994-02-28 2009-05-05 The Procter & Gamble Company Structural elastic-like nonwoven web
US5947948A (en) * 1994-02-28 1999-09-07 The Procter & Gamble Company Absorbent article with multiple zone structural elastic-like film web extensible leg flap panels
US5554145A (en) * 1994-02-28 1996-09-10 The Procter & Gamble Company Absorbent article with multiple zone structural elastic-like film web extensible waist feature
US5993432A (en) * 1995-12-04 1999-11-30 The Procter & Gamble Company Web materials having elastic-like and expansive zones
US6007898A (en) * 1995-12-22 1999-12-28 Hna Holdings, Inc. Thermoplastic three-dimensional fiber network
US5731062A (en) * 1995-12-22 1998-03-24 Hoechst Celanese Corp Thermoplastic three-dimensional fiber network
US5747144A (en) * 1996-04-03 1998-05-05 Rubie's Costume Co., Inc. Costumes with semi-rigid fabric components and method of manufacture of same
USRE37533E1 (en) 1996-04-03 2002-01-29 Rubie's Costume Co., Inc. Costumes with semi-rigid fabric components and method of manufacture of same
WO1997036740A1 (en) * 1996-04-03 1997-10-09 Rubie's Costume Co., Inc. Costumes with semi-rigid fabric components and method for manufacture of same
US5650214A (en) * 1996-05-31 1997-07-22 The Procter & Gamble Company Web materials exhibiting elastic-like behavior and soft, cloth-like texture
US6342287B1 (en) * 1996-09-27 2002-01-29 Pandrol Limited Elastic pad, especially under-rail
WO2004098869A1 (en) 2003-05-05 2004-11-18 North Carolina State University Three-dimensional deep molded structures with enhanced properties
US20060228528A1 (en) * 2004-10-29 2006-10-12 Eberhard Link Deep draw process for flame retardant materials

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